Nick Sonnentag is a Senior Principal Engineer at Oshkosh, where he contributes to the development of some of the world’s toughest vehicles using additive manufacturing (AM). Drawing on experience from ATI, DuPont, and more, Nick possesses broad and deep expertise in 3D printing. In this episode of the 3DPOD, we discuss alloys, vehicle manufacturing, applications, and the readiness of directed energy deposition technology for widespread use. Not limiting his exploration of 3D printing to his work at Oshkosh, Nick founded Sunnyday Technologies to tackle the significant challenges in construction 3D printing. Rather than focusing on machines, he concentrates on the binders and the precise formulations needed to achieve specific properties in final structures. This approach stands out for its elegance and promise, diverging from conventional methods of discovering applications and materials. It makes this episode especially insightful.

Nick also wanted to clarify that at one point, he mistakenly referenced General Atomics instead of General Dynamics and asked me to note this for accuracy.

Kevin Ayers spent 30 years at the FBI, contributing to groundbreaking engineering initiatives for the Bureau and beyond. On this episode of the 3DPOD, we’re fortunate to have Kevin sharing some of his once-classified insights on our podcast. It’s fascinating to learn how the FBI utilized 3D printing and just how long they’ve been exploring this technology.

In addition to his FBI tenure, Kevin has been instrumental in 3D printing’s success for nearly two decades, worked at Danfoss, and currently serves as a consultant at 3D Metal Konsulting. His cumulative expertise and perspectives are truly remarkable, making this episode a must-listen.

Andy Davis is Director of Government Solutions at The Barnes Global Advisors. Previously he was at the DOD and the US Army in various logistics, program management, technology advisory roles. In the podcast we discuss austere 3D printing, 3D Printing at the point of need, drones, the military at large and much more. It’s clear that the Navy and Air Force are investing in AM and we delve into the why and what of it. Andy´s views and opinions are steeped in experience and this is a very helpful episode to any coming to grips with military uses for Additive. 

Kate Black is the Chief Executive Officer of Atomik AM, where she leads a team dedicated to fostering innovation and developing integrated advanced manufacturing solutions. The company specializes in electronics 3D printing, jetting technologies for novel materials, coatings, and multi-material 3D printing. Additionally, she serves as a Professor of Manufacturing at the University of Liverpool. In this episode of the 3DPOD, Kate shares her technical vision and a forward-looking perspective that will captivate many. She also emphasizes the importance of environmental manufacturing, advocating for cleaner chemistries and technologies.

Melissa Orme played a pivotal role as CTO at Morf3D, transforming the company from a standard service bureau into a leader in aerospace 3D printing that went on to be acquired by Nikon. Now at Boeing, as Vice President of Additive Manufacturing (AM), she spearheads the company’s 3D printing initiatives, aiming to integrate AM wherever practical. Boeing, which has a longstanding lead in low-rate 3D printing production and manufacturing thousands of parts for civilian aircraft, benefits from Melissa’s vision and expertise. In this episode of the 3DPOD, she shares fascinating insights about Boeing’s current advancements and her aspirations for expanding 3D printing’s applications within the company.

Sascha Schwarz is a researcher dedicated to aiding his university, Technical University of Munich (TUM), to foster innovation as CTO of TUM Venture Labs. In this episode of the 3DPOD, we explore diverse startups, the challenges faced by scientists transitioning into entrepreneurial roles, and the incubation of new ventures. Topics include technology transfers, development, and the essential qualities of a successful startup. This conversation is a must-listen for university professionals looking to commercialize technology and for entrepreneurs seeking to gain valuable insights from Sascha’s expertise.

Tim Simpson is an advisor to NASA, Professor Emeritus at Penn State, and a consultant for Xact Metal. He is also associated with The Barnes Global Advisors, among numerous other engagements. In this episode of the 3DPOD, our discussion delves into defense, space, and the future of additive manufacturing, exploring critical topics such as commoditization, drones, and advancements in software. It’s an engaging conversation for anyone keen to understand the current state and trajectory of additive technology.

Jim Harrison is a true 3D printing veteran. Currently working at MELD Manufacturing, he has also contributed his expertise to nScrypt, Cimquest, and other notable organizations. As a co-founder of one of the world’s first service bureaus and an early pioneer in vat polymerization for medical devices, he operated one of the earliest vat polymerization printers at Pratt & Whitney. Jim’s insights and vision not only highlight the evolution of additive manufacturing but also underscore the progress made over decades in the industry.

Trent Esser founded Printerior with his partners and has since pivoted and redefined the company’s focus multiple times. Printerior operates as a 3D printing service that both sells and recycles filament. The company employs a diverse range of equipment, including inexpensive desktop machines, Bambu Lab systems, and large-format printers.

Despite producing hundreds of thousands of parts, Printerior has chosen to forgo powder bed fusion, instead focusing on material extrusion. This approach allows the company to remain more fluid and flexible than many of its competitors. In my view, Printerior represents a vanguard reshaping how 3D printing services are delivered.

Harshil Goel founded Dyndrite as a kernel designed for 3D printing. While this core technology remains available for OEMs and software firms, the company now also offers a tool that provides users with greater control over laser operations and settings. In this episode of the 3DPOD, Harshil explains what Dyndrite does and how it is being utilized. We discuss innovative approaches to using, modifying, and adapting settings, as well as methods to accelerate manufacturing processes. Faster build rates and enhanced performance customization are among the topics covered in our conversation.